Eton Viper 70 Silver Service Manual
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Eton Viper 70 Silver Service Manual

2009 viper silver series
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ETON America
2009 VIPER SILVER SERIES
SERVICE MANUAL
Covers:
Viper 70 Silver
Viper 90 Silver
Viper 90R Silver

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Summary of Contents for Eton Viper 70 Silver

  • Page 1                       ETON America 2009 VIPER SILVER SERIES SERVICE MANUAL Covers: Viper 70 Silver Viper 90 Silver Viper 90R Silver...

  • Page 2: Table Of Contents

    CONTENTS 1. INFORMATION 2. MAINTENANCE 3. ENGINE REMOVAL AND INSTALLATION 4. LUBRICATION 5. CYLINDER HEAD / VALVES 6. CYLINDER / PISTON 7. TRANSMISSION / KICK STARTER 8A. TRANSMISSION GEAR SET 8B. SHIFTING / GEAR BOX (ONLY FOR VIPER 90R) 9. STEERING SYSTEM 10.

  • Page 3: Information

    1. INFORMATION 1.1 GENERAL SAFETY 1.4 SERIAL NUMBER 1.2 NOTES 1.5 TORQUE VALUES 1.3 SPECIFICATION 1.1 GENERAL SAFETY Gasoline WARNING Gasoline is extremely flammable and explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN Carbon Monoxide WARNING Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

  • Page 4: Air Filter

    1.3 SPECIFICATION GENERAL SPECIFICATIONS Item Standard Model code VIPER 70 VIPER 90 VIPER 90R Dimensions Overall length 1,510 mm (59.4 in) 1,500 mm (59.1 in) Overall width 850mm (33.4 in) 850 mm (33.4 in) Overall height 890 mm (35.0 in) 900 mm (35.4 in) Seat height 670 mm (26.4 in)
  • Page 5 Item Standard Model code VIPER 70 VIPER 90 VIPER 90R Fuel Type Unleaded gasoline only Fuel tank capacity Plastic 4.5 L (0.99 lmp gal, 1.17 US gal) Iron 3.6 L (0.79 lmp gal, 0.94 US gal) Fuel reserve amount Plastic 1.2 L (0.26 Imp gal, 0.31 US gal) Iron 1.0 L (0.22 Imp gal, 0.26 US gal)
  • Page 6 ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit 7.00 ~ 7.40 cm 0.05 mm (0.43 ~ 0.45 cu.in) (0.002 in) Cylinder Bore size 47.000 ~ 47.010 mm 47.10 mm (1.8504 ~ 1.8508 in) (1.8543 in) Taper limit ---- 0.05 mm (0.002 in) Maximum out-of-round ----...
  • Page 7 Item Standard Limit Rocker arm/rocker arm shaft Rocker arm inside diameter 10.000 ~ 10.015 mm 10.100 mm (0.3937 ~ 0.3943 in) (0.3976 in) Rocker arm shaft outside diameter 9.972 ~ 9.987 mm 9.910 mm (0.3902 in) (0.3926 ~ 0.3932 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034 mm 0.19 mm...
  • Page 8 Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.02 mm (0.0008 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in)
  • Page 9 Item Standard Limit Compressed pressure ---- 74 ~ 90 N at 25.45 mm installed) 7.52 ~ 9.18 kg, 20.15 ~ 24.60 lb at 1.00 in) ---- 74 ~ 90 N at 25.45 mm 7.52 ~ 9.18 kg, 20.15 ~ 24.60 lb at 1.00 in) °/1.2 mm Tilt limit °/0.05 in)
  • Page 10 Item Standard Limit Piston rings Top ring Type ---- Barrel 1.0 × 2.1 mm ---- Dimensions (B × T) (0.0394 × 0.0827 in) 0.45 mm End gap (installed) 0.10 ~ 0.25 mm (0.0177in) (0.0039~0.0098in) 0.09 mm Side clearance (installed) 0.015 ~0.055 mm (0.0006~0.0022in) (0.0035in) 2nd ring...
  • Page 11 Item Standard Limit Clutch Clutch type Automatic centrifugal ---- Clutch shoe thickness 3.5 ~ 4.0 mm 0 mm (0.1338 ~0.1575 in) (0.078 in) 3.5 ~ 4.0 mm Clutchshoe spring free length ---- Clutch housing inside diameter 107.0 ~107.2 mm 107.5 mm (4.21 ~4.22 in) (4.23in) Compression spring free length...
  • Page 12 Item Standard Limit Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0.04 ~ 0.12mm 0.15 mm (0.0016 ~ 0.0047 in) (0.006 in) Outer-rotor-to-oil-pump-housing clearance 0.14 ~ 0.21 mm 0.28 mm (0.0055 ~ 0.0083 in) (0.0110 in) Oil-pump-housing-to-inner-rotor-and-outer- 0.06 ~ 0.11 mm 0.20 mm rotor clearance (0.0024 ~ 0.0043 in)
  • Page 13 CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Shock absorber travel 30 mm (1.18 in) ---- Optional spring ---- Rear suspension Shock absorber travel 40 mm (1.57 in) ---- Optional spring ---- Front wheel Type Panel wheel ---- 7 × 5 AT Rim size ---- VIPER 70...
  • Page 14 Item Standard Limit Brake lever and brake pedal Brake lever free play (pivot) front 4.0 ~ 7.0 mm (0.16 ~ 0.28 in) ---- rear 0 ~ 1.5 mm (0 ~ 0.06 in) ---- Throttle lever free play 1.0 ~ 3.0 mm (0.04 ~ 0.12 in) ----...
  • Page 15 ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 13.0 °/1,700 r/min ---- Advanced timing (B.T.D.C.) 29°/4,000 r/min ---- Advancer type Electrical (analogue) ---- C.D.I. Magneto model/manufacturer C1120-A26-6000/SHIHLIN ---- Ω Pickup coil resistance/color 94 ~ 140 at 20 °C (68 °F)/ ---- White/Blue—Red...
  • Page 16 Item Standard Limit Electric starter system Type Constant mesh ---- Starter motor Model/manufacturer C1200-A26-6000/SY ---- Output 0.35 kW ---- Ω Armature coil resistance 0.014 ~ 0.019 at 20 °C (68 ° ---- Brush overall length 7.0 mm (0.24 in) 3.5 mm (0.14 in) Brush overall length 1.0 ~ 3.0 N...

  • Page 17: Serial Number

    1.4 SERIAL NUMBER Every E-TON’s ATV has a serial number which is stamped on each frame and engine. The position of the serial number is shown in the pictures below. Make sure the serial number is the same as in your owner’s manual.

  • Page 18: Torque Values

    1.5 TORQUE VALUES Make sure every torque value is correct when you assemble the engine & frame. Please follow the torque values list to assemble your ATV. FRAME Tightening torque Thread Part to tightened Remarks size kg-m ft.lb Handlebar upper holder bolt 12-15 1.2-1.5 8.9-11.1...
  • Page 19 ENGINE Tightening torque Thread Part to tightened Remarks size kg-m ft.lb Spark plug 10-12 1.0-1.2 7.4-8.9 Cylinder head bolts 10-14 1.0-1.4 7.4-10.3 Tappet adjusting nut 7-11 0.7-1.1 5.2-8.1 Oil drain bolt 20-30 2.0-3.0 14.8-22.1 Clutch outer nut 39-41 3.9-4.1 28.8-30.2 Loctite 638 Drive face nut 54-56...

  • Page 20: Maintenance

    2. MAINTENANCE 2.1 MAINTENANCE SCHEDULE 2.8 DRIVE CHAIN 2.9 BRAKE SYSTEM 2.2 FUEL TUBE 2.10 WHEELSAND TIRES 2.3 THROTTLE OPERATION 2.11 STEERINGSYSTEM 2.4 THROTTLE CABLE ADJUSTMENT 2.12 TOE-IN 2.5 AIR CLEANER 2.6 SPARK PLUG 2.13 GEAR & ENGINE OIL 2.7 IDLE SPEED 2.1 MAINTENANCE SCHEDULE The maintenance times in this table are based upon average riding conditions.

  • Page 21: General Maintenance And Lubrication Chart

    General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check chain tension. Timing chain √ √ √ √ Adjust if necessary. Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary.
  • Page 22 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Moving parts and • Lubricate. √ √ √ √ cables Drive select lever • Check operation and adjust or replace if neces- √...

  • Page 23: Throttle Cable Adjustment

    2.3 THROTTLE OPERATION Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kinking in the throttle cable, replace it if necessary. Check the throttle lever, free play is 5-10 mm at the tip of the throttle lever.

  • Page 24: Spark Plug

    2.6 SPARK PLUG This spark plug is located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Check the spark plug electrodes for wear. Install a new spark plug if the electrodes and insulator tip appear unusually fouled or burned.
  • Page 25 Adjust the chain slack Loosen the locked bolts (4 pcs) then adjust the drive chain slack by turn the adjusting nut. Tighten the four locked bolts. When the drive chain becomes very dirty, it needs be removed, cleaned and lubricated. Use a commercial chain lubricant to lubricate the drive chain.

  • Page 26: Brake System

    2.9 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage. Replace or repair it if necessary. Measure the free play of the brake lever at the end of the brake lever. The standard of free play is 15-25 mm. There is a parking brake located at the rear tire.
  • Page 27 2.11 STEERING SYSTEM Check the free play of the steering shaft with the front wheels centered straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing, and ball joint. 2.12 TOE-IN Set the vehicle on level ground and set the front wheels facing straight ahead.
  • Page 28 2.13 GEAR & ENGINE OIL Gear oil needs to be changed every year. There is a gear oil release bolt at the rear of engine. Loosen this release bolt and let the dirty oil flow out. The refilling oil hole is on the engine case beside gearbox. Please refer to Chapter 4...

  • Page 29: Engine Removal And Installation

    3. ENGINE REMOVAL AND INSTALLATION 3.1 SERVICE INFORMATION 3.3 ENGINE INSTALLATION 3.2 ENGINE REMOVAL 3.1 SERVICE INFORMATION ENGINE SH BE REMOVED IN THE CONDITION OF NECESSARY REPAIR OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM 3.2 ENGINE REMOVAL Remove the seat and rear fender. (Chapter 11) Remove the spark plug cap from the spark plug.

  • Page 30: Engine Installation

    Remove the tow engine hanger nuts and bolts. Remove the engine from the right side of frame. 3.3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 24-30 Nm Route the wires and cable in reverse order properly.

  • Page 31: Lubrication

    4. LUBRICATION 4.4 ENGINE OIL & FILTER CHANGE 4.1 SERVICE / GENERAL INFORMATION 4.2 TROUBLESHOOTING 4.5 OIL PUMP REMOVAL 4.3 ENGINE OIL LEVEL 4.1 SERVICE / GENERAL INFORMATION This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump.
  • Page 32 ITEM STANDARD SERVICE OIL PUMP Body-to-rotor clearance ---------- 0.12 ---------- Rotor tip clearance 0.12 End clearance 0.05 - 0.10 TORQUE VALUE OIL DRAIN BOLT 20-30 N.m 4.2 TROUBLESHOOTING Oil lever too low-high oil consumption Normal oil consumption. External oil leaks. Worn piston rings.
  • Page 33 4.3 ENGINE OIL LEVEL Place the engine on level plane. Check the oil level with the oil level gauge it in when making this check. Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge.
  • Page 34 Remove the oil filter cap, spring and oil filter screen. Check the O-ring for damage or fatigue. Install a new oil filter screen and spring then install the cap. OIL FILTER SCREEN OIL FILTER CAP O-RING SPRING...
  • Page 35 Install the oil drain bolt with sealing washer. TORQUE: 20-30 N.m OIL DRAIN BOLT Fill the crankcase with recommended oil. ENGINE OIL CAPACITY: 0.8 liter at draining. Install the oil filter cap. Install the oil level gauge. Start the engine and let it idle speed for 2 or 3 minutes.
  • Page 36 Remove the cooling fan composition. COOLING FAN COMPOSITION Remove the A.C.G generator assy. A.C.G GENERATOR ASSY Remove the right crankcase cover.
  • Page 37 Remove the oil pump driven sprocket. OIL PUMP DRIVEN SPROCKET Remove the oil pump assy. OIL PUMP ASSY Disassemble the oil pump.
  • Page 38 INSPECTION Measure the oil pump body-to-rotor clearance. SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measure the pump rotor tip clearance. SERVICE LIMIT: 0.12 mm Remove the oil pump shaft and measure the pump end clearance. SERVICE LIMIT: 0.2 mm.
  • Page 39 OIL PUMP ASSEMBLY / INSTALLATION Install the oil pump assy. OIL PUMP ASSY Install the oil pump driven sprocket. OIL PUMP DRIVEN SPROCKET Install the A.C.G generator assy and cooling fan A.C.G GENERATOR ASSY composition. COOLING FAN COMPOSITION...

  • Page 40: Cylinder Head / Valves

    5. CYLINDER HEAD / VALVES 5.4 CYLINDER HEAD REMOVAL 5.1 SERVICE / GENERAL INFORMATION 5.2 TROUBLESHOOTING 5.5 CYLINDER HEAD ASSEMBLY 5.3 CAMSHAFT COMPOSITION 5.1 SERVICE / GENERAL INFORMATION This section describes cylinder head, valves, camshaft and the other parts maintenance. The engine must be removed from the frame to service cylinder head.
  • Page 41 5.3 CAMSHAFT COMPOSITION REMOVAL Remove the cylinder head cover. HEAD COVER Remove the air cleaner and carburetor. CARBURETOR Remove the inlet pipe assy. Remove the shroud compositions. INLET PIPE SHROUD COMPOSITION Relax the cam chain adjuster screw. CAM CHAIN ADJUSTING BOLT...
  • Page 42 Remove the nuts and washers. Remove the camshaft holder and dowel pins. Relax the camshaft gear from cam chain and remove the camshaft. NUTS HOLDER CAMSHAFT CAMSHAFT GEAR INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage. 25.583 mm SERVICE LIMIT:...
  • Page 43 Inspect the camshaft and bearings for wear or damage and replace them if necessary. BEARINGS Screw a 5mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms. Inspect the camshaft holder, rocker arms and rockerarm shafts for wear or damage.
  • Page 44 Measure the I.D. of each rocker arm. SERVICE LIMIT: 10.10mm Measure the O.D. of each rocker arm shaft. SERVICE LIMIT: 9.91mm 5.4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head. Remove the cylinder head gasket and dowel pins.
  • Page 45 Remove the cam chain guide. CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve VALVE COTTERS springs with a valve spring compressor. SPRING RETAINERS VALVE SPRINGS INSPECTION Clean off all carbon deposits from the combustion chamber. Check the spark plug hole and valve area for cracks.
  • Page 46 Measure the cylinder head diagonally for warp with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm Measure the free lenght of the inner and outer OUTER VALVE SPRING valve springs. SERVICE LIMITS: Inner 27.0 mm Outer 30.5 mm INNER VALVE SPRING Inspect each valve for turning, burning, scratches or abnormal stems wear.
  • Page 47 Check the valve movement in the guide. Measure and record each valve stem O.D. SERVICE LIMITS: 4.90 mm Measure and record the valve guide I.D. SERVICE LIMITS: IN / EX 5.03 mm Calculate the stem-to-guide clearance. SERVICE LIMITS: IN 0.08 mm EX 0.10 mm NOTE: If the stem-to-guide clearance exceeds the service limits, determine if a new...
  • Page 48 INSTALLATION Install the new gasket and dowel pins. Install the cam chain guide. Install the cylinder head...
  • Page 49 CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder. Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter-clockwise. Position the camshaft gear with cam chain so that its “I”...
  • Page 50 Install the dowel pins and camshaft holder. Tighten the washers and nuts. TORQUE: 14-16 N.m Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge. STANDARD VALVE: 0.07 mm TORQUE: 7-11 N.m Relax the cam chain adjusting bolt with counterclockwise direction and install the o-ring and screw.
  • Page 51 Install the cylinder head cover. screw and install the carburetor cap to the carburetor.

  • Page 52: Cylinder / Piston

    6. CYLINDER / PISTON 6.4 PISTON REMOVAL 6.1 SERVICE INFORMATION 6.2 TROUBLESHOOTING 6.5 PISTON INSTALLATION 6.5 CYLINDER INSTALLATION 6.3 CYLINDER REMOVAL 6.1 SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil in the cylinder head and engine case.
  • Page 53 6.3 CYLINDER REMOVAL Remove the cylinder head. CYLINDER HEAD Remove the cylinder. Remove the cylinder gasket and dowel pins.
  • Page 54 Clean off any gasket materials from the cylinder surface. NOTE: Be careful not to damage the gasket surface. 6.4 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase.
  • Page 55 Spread each piston ring and remove it by lifting up at a point opposite the gap. INSPECTION Inspect the cylinder walls for scratches or wear.
  • Page 56 Measure and record the cylinder I.D. at three levels in both an X and Y axis. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 47.1 mm Calculate cylinder taper at three levels in an X and Y axis. Take the maximum reading to determine the taper.
  • Page 57 PISTON / PISTON RING INSPECTION Measure the piston ring-to-groove clearance. SERVICE LIMITS: TOP 0.09 mm SECOND 0.09 mm Inspect the piston for wear or damage. PISTON Insert each piston ring into the cylinder and measure the ring end gap. NOTE: Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder.
  • Page 58 Measure the piston pin O.D. SERVICE LIMIT: 12.96 mm Measure the piston pin bore. SERVICE LIMIT: 13.04 mm Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.02 mm...
  • Page 59 Measure the connecting rod small end I.D. ● CONNECTING ROD SERVICE LIMIT: 13.06 mm 6.5 PISTON INSTALLTION PISTON RING INSTALLATION ● Clean the piston ring grooves thoroughly and installthe piston ring with the mark facing up. NOTE: Don’ t interchange the top and second rings.
  • Page 60 PISTON INSTALLATION Install the piston with it’ s “ IN “ mark on the ● intake valve side. Install the piston pin with new pin clips. ● Do not align the piston pin clip end gap with ● the piston cutout. NOTE: Do not allow the clip to fall into the Crank case.
  • Page 61 ● Install the dowel pins and a new gasket. Coat the cylinder bore and piston rings with ● engine oil and install the cylinder. NOTE: piston rings damage cylinder bore during installation. Do not allow the cam chain fall into the crankcase. Install the cylinder head.

  • Page 62: Transmission / Kick Starter

    7. TRANSMISSION / KICK STARTER 7.1 SERVICE INFORMATION 7.4 KICK STARTER 7.2 TROUBLESHOOTING 7.5 KICK STARTER ASSEMBLY 7.3 C.V.T DISASSEMBLY L CRANK 7.6 C.V.T ASSEMBLY CASE COVER REMOVAL 7.1 SERVICE INFORMATION If the drain tube assy fills with water, the tube should be drained. ●...
  • Page 63 7.3 C.V.T DISASSEMBLY L CRANK CASE COVER REMOVAL Relax the band screw and remove the C.V.T inlet duct. ● ● Remove the bolts and L crank case cover.
  • Page 64 Remove the gasket and dowel pins. ● ● Clean off any gasket material from L crank case surface. C.V.T REMOVAL ● Relax the flange nut and remove kick-starter ratchet. ● Remove the drive face.
  • Page 65 ● Relax the flange nut. ● Remove the drive pulley assy and d riven belt. ● Remove the drive face boss and movable driven face assy. ● Remove the ramp plate and weight roller set.
  • Page 66 Relax the special nut and remove the driven plate ● composition and driven face spring. INSPECTION ● Inspect the driven belt for wear, tear or damage. ● Measure the width of driven belt. SERVICE LIMIT: 17.0 mm DRIVEN ● Inspect the weight roller for wear or damage and WEIGHT replace them if necessary.
  • Page 67 Measure the I.D. of movable driven face. ● SERVICE LIMIT: 21.24m m Inspect the drive face collar for wear or damage. ● ● Inspect the drive face boss for wear or damage. ● Measure the O.D. of drive face boss. SERVICE LIMIT: 20.94m m ●...
  • Page 68 ● Inspect the clutch weight set for wear or damage. CLUTCH WEIGHT ● Measure the thickness of clutch weight lining. SERVICE LIMIT: 2.0m m ● Measure the length of driven face spring. SERVICE LIMIT: 82.6 mm ● Inspect the driven face assy and replace them if necessary.
  • Page 69 7.4 KICK STARTER This kick-starter arm is on the left side of engine. When the kick-starter arm is kicked, the gear of start shaft will drive the kick start er to revolve the crank shaft to start the engine. After the engine is started, the kick-starte will stop transfer the power to the kick-starter driven gear.
  • Page 70 KICK STARTER DISASSEMBLY ● Remove the L crank case cover. ● Remove the kick starter. Remove the ex. c ir clip and washer from kick starter ● spindle composition.
  • Page 71 ● Rotate the kick starter spindle composition to rem ove the kick driven gear and spring. ● Remove the kick starter spindle composition and return spring. ● Remove the kick spindle bush. KICK STARTER SPINDLE COMPOSITION INSPECTION ● Inspect the kick starter spindle composition for wear or damage.
  • Page 72 Inspect the kick driven gear and spring for wear or ● KICK DRIVEN damage. ● Inspect the machining surface for wear or damage. MACHINING 7.5 KICK STARTER ASSEMBLY ● Install the kick spindle bush, return spring and spindle assy. ● Install the kick driven gear and spring.
  • Page 73 7.6 C.V.T ASSEMBLY ● Put together the driven face assy, spring, and driven plate composition. ● Compose the movable driven face composition, weight roller set, and drive face. ● Install the movable drive face assy and boss.
  • Page 74 Install the drive face and kick starter ratchet. ● ● Install the driven belt and driven pulley assy. ● Install the dowel pins and gasket.
  • Page 75 ● Install the L crank case cover.

  • Page 76: Transmission Gear Set

    8A. TRANSMISSION GEAR SET 8A.1 SERVICE INFORMATIONF 8A.4 GEAR SET INSPECTION 8A.2 TROUBLESHOOTING 8A.5 GEAR SET INSTALLATION 8A.3 GEAR SET REMOVAL 8A.1 SERVICE INFORMATION GENERAL ● mission gear set repair, the engine must from frame. ● Fill the recommend oil after reassembl mission cover.
  • Page 77 8A.3 GEAR SET REMOVAL Remove the drain bolt and drain the oil. ● the bolts and remove the ion cover. Remove the dowel pins and gasket. Pull the shaft gearshifts out and remove the fork shift. Remove the reverse shaft comp, and counter shaft comp.
  • Page 78 Remove the sprocket and fixing plate from the final shaft comp. Remove the cir clip and final shaft comp.
  • Page 79 8A.4 GEAR SET INSPECTION Turn the inner race of the bearing with your finger. ● The bearing should turn smoothly and quietly. ● Also check that the outer races of the bearings fit tightly in the left crankcase. ● Replace the bearings if they are abnormal.
  • Page 80 8A.5 GEAR SET INSTALLATION ● Install the mission cover and final shaft gear comp together with cir clip. ● Install the counter shaft comp and reverse shaft comp in the left crankcase. ● Install the shaft gearshifts and the fork shift.

  • Page 81: Shifting / Gear Box (Only For Viper 90R)

    8B. SHIFTING / GEAR BOX (ONLY FOR VIPER 90R) 8B.1 SERVICE INFORMATIONF 8B.4 SHIFT MECHANISM 8B.2 TROUBLESHOOTING 8B.5 GEAR BOX 8B.3 THE PARTS DRAWING OF TRANSMISSION SYSTEM 8B.1 SERVICE INFORMATIONF GENERAL ● FOR MISSION GEAR SET REPAIR, THE ENGINE MUST FROM FRAME.
  • Page 82 8B.3 THE PARTS DRAWING OF TRANSMISSION SYSTEM...
  • Page 83 Shift Mechanism Gear Box 8B.4 SHIFT MECHANISM C.D.I It include VIPER 90R control system. Replace if control system hen this wire connected, the engine speed is limited to 4800 r/min. hen this wire top engine speed (8000 r/min) is available. (VIPER 90 R C.D.I WIRE...
  • Page 84 Sensor Inspect wire for break or damage and check contact. easure fig-1 fig-1 If length is below 30mm, it must be replaced. octite 5699 and with torque 25 kgf-cm. SERVICE LIMIT: 30 mm TORQUE: kgf-cm Shift fixed Spring, Shift Push, Shaft Fixed Fork Remove mission cover and other parts.
  • Page 85 Shift Motor Check shift motor for proper action using the following data: torque Voltage(v) Current(mA) (kg-cm) loaded ≤800 No load ≤390 Replace it if necessary. 8B.5 GEAR BOX Shift Motor Reverse gear Comp Fork Shift Counter Shaft Comp Remove transmission cover and parts of shift mechanism. Inspect gears for wear, scoring, chipping, or breaking.

  • Page 86: Steering System

    9. STEERING SYSTEM 9.1 THE PARTS DRAWING OF 9.3 HANDLEBAR STEERING SYSTEM 9.2 TROUBLESHOOTING 9.4 STEERING SYSTEM 9.1 THE PARTS DRAWING OF STEERING SYSTEM...
  • Page 87 9.2 TROUBLESHOOTING HARD STEERING FAULTY TIRE STEERING SHAFT HOLDER TOO TIGHT INSUFFICIENT TIRE PRESSURE FAULTY STEERING SHAFT BEARINGS DAMAGED STEERING SHAFT BEARING 9.3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right handle bar. Remove brake lever bracket. Remove engine switch housing on the left handle bar. Remove rear brake level bracket.
  • Page 88 9.4 STEERING SYSTEM REMOVAL OF KINGPIN AND TIE-ROD Remove the front wheels and brakes plates. Remove the four self-lock nuts from the tie-rod ball joints and take off the two tie-rods. Take off the rubber cap on the kingpin and remove the cotter pins on the kingpin.
  • Page 89 KINGPIN BUSHING INSPECTION There are two bushing in the sleeve of front swing arm, the upper and lower bushing. Check the kingpin bushings for wear or damage. Measure the inner diameter of the bushings. Upper minimum limit: Ø15.69 mm Lower minimum limit: Ø17.19 mm STEERING SHAFT REMOVAL Remove the handle bar and handle bar cover.
  • Page 90 STEERING SHAFT INSPECTION Inspect the steering shaft for damage or cracks. Measure the steering shaft outer diameter in the location of the bushing. Minimum limit: Ø22.0 mm STEERING SHAFT BEARING INSPECTION Turn the shaft bearing with finger. The bearing is on the front part of frame. The bearing should turn smoothly and quietly.
  • Page 91 INSTALLATION OF TIE -ROD Install the ball joint with “ L” mark on the steering shaft side. Install the tie-rod with the mark on the wheel side. Let the distance between the ball joints be 164 mm for RXL 50/70/90 and RXL90R and RXL50M. This is temporary setting.

  • Page 92: Front Wheel System

    10. FRONT WHEEL SYSTEM 10.1 THE PARTS DRAWING OF 10.3 FRONT WHEEL FRONT WHEELS SYSTEM 10.2 TROUBLESHOOTING 10.4 FRONT BRAKES 10.1 THE PARTS DRAWING OF FRONT WHEELS SYSTEM...

  • Page 93: Front Wheel

    10 .2 TROUBLESHOOTING FRONT WHEEL WOBBLING FAULTY TIRE WORN FRONT BRAKE DRUM BEAR ING BENT RIM AXLE NUT NOT TIGHTENED PROPERLY BRAKE DRAG INCORRECT BRAKE ADJUSTMENT STICKING BRAKE CABLE BRAKE SHOES WORN POOR BRAKE PERFORMANCE WORN BRAKE DRUM BRAKE LININGS OILY, GREASY OR DIRTY IMPROPER BRAKE ADJUSTMENT 10 .3 FRONT WHEEL...

  • Page 94: Front Brakes

    10 .4 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel. Remove the brake drum. Measure the brake lining thickness. The minimum limit: 1.5 mm If they are thinner than the minimum limit, replace the brake linings.
  • Page 95 Measure the brake drum inner diameter. The maximum limit: 86 mm Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly. If the race does not turn smoothly or quietly, remove and discard the bearings BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm.
  • Page 96 Remove brake arm and cam. Remove return spring. Remove indicator plate and felt seal. INSTALL BRAKE PANAL Apply grease to the brake cam and anchor pin and install the cam in the brake panel. Soak the felt seal in the engine oil and install the seal on the brake cam.
  • Page 97 Install the brake panel on the knuckle. Connect the brake cable to the brake arm. Install the brake arm cover. Tighten the screws securely. Position the brake shoes in their original locations and install the brake shoe spring. Install the brake drum and front wheel. Install the castle nut and cotter pin.

  • Page 98: Rear Wheel And Brake System

    11. REAR WHEEL AND BRAKE SYSTEM 11.1 THEPARTSDRAWINGOFREAR 11.3 DRIVEMECHANISM WHEELSYSTEM 11.2 TROUBLESHOOTING 11.4 HYFRAULICDISCBRAKE SYSTEM 11.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM...
  • Page 99 11 .2 TROUBLESHOOTING BAD BRAKE PERFORMANCE BRAKE SHOES ARE WORN BAD BRAKE ADJUSTMENT BRAKE LININGS ARE OILY, GREASY OR DIRTY BRAKE DRUMS ARE WORN BRAKE ARM SETTING IS IMPROPERLY ENGAGE VIBRATION OR WOBBLE AXLE IS NOT TIGHTENED WELL BENT RIM AXLE BEARINGS ARE WORN FAULTY TIRES REAR AXLE BEARING HOLDER...
  • Page 100 Disassemblies the chain retaining clip and master link. Disassembly the driven sprocket, axle and sprocket collar. Check the driven sprocket for damage or wear. Let the rear axle lie in V -blocks and check the run out. The run out limit is 0.5 mm Check the turning of bearing with fingers.
  • Page 101 INSTALLATION Add grease to the dust seal lips and install dust seals. Assembly the rear axle and the driven sprocket. Assembly the drive chain on the driven sprocket. Assembly the master link and retaining clip. Note the retaining clip direction. Install the drive chain cover.
  • Page 102 11 .4 HYFRAULIC DISC BRAKE SYSTEM To replace brake disc To replace brake disc Remove the rear left tire...
  • Page 103 Unscrew the two bolts shown on the photo and remove caliper Unscrew the rear wheel axle nut and then remove the mounting seat of the disc Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm...
  • Page 104 TO REPLACE THE BRAKE SHOE Remove the rear left tire Loosen the two bolts as shown in the photo and remove caliper Press the plate to the end Remove the brake shoe as shown in fig...
  • Page 105 Check the thickness of brake shoe and replace a new one if the thickness less than 1mm. Press the piston to the end prior to installation of brake shoe TO REPLACE THE BRAKE HYDRAULIC OIL Loosen the bolts and open the cover.
  • Page 106 Loosen the bolt and drain out the used brake oil. Tighten the bolt after the used oil being drained out completely. Add the brake oil (Dot 3 or Dot 4) Keep oil level at least half of the cup to avoid air gets into brake system, such like caliper and tube Loosen the bolt to vent air from brake system.
  • Page 107 Pull left brake lever slightly to extract air from brake system Fill the brake oil to the level as shown in the cup when no air comes out Assemble the cover...

  • Page 108: Fenders And Exhaust Pipe

    12. FENDERS AND EXHAUST PIPE 12.1 FENDERS DRAWING 12.4 EXHAUST PIPE REMOVE 12.2 HOW TO REMOVE THE FENDERS 12.5 EXHAUST PIPE INSTALLATION 12.3 EXHAUST PIPE DRAWING 12.1 FENDERS DRAWING...

  • Page 109: How To Remove The Fenders

    12.2 HOW TO REMOVE THE FENDERS Loosen two plastic bolts, you can remove the front body covers as shown in picture 1 & 2. Picture 1 Picture 2 You need to remove the seat before removing the front and rear fender. Loosen the bolts as shown in pictures 3 &...
  • Page 110 As picture 5 you can remove the rear R/L fender. As picture 6 unscrew these four bolts then you can remove the rear body fender.
  • Page 111 Before remove the front body cover you have to remove the handle bar cover fristly. Picture 7 Secondly, you need to disassembly the front and rear brake cable and throttle cable, then disassembly the handle bar. Loosen the bolt then you can remove the front body fender (Picture 7).
  • Page 112 12.3 EXHAUST PIPE DRAWING...

  • Page 113: Exhaust Pipe Remove

    12.4 EXHAUST PIPE REMOVE CAUTION Do not service the exhaust pipe while they are hot. Loosen the exhaust pipe nuts that fixed with engine. Remove the exhaust pipe mounting bolts that beside the muffler body. Remove the exhaust pipe carefully. 12.5 EXHAUST PIPE INSTALLATION Installation is the reverse order of removal.

  • Page 114: Electrical System

    13. ELECTRICAL SYSTEM 13.1 TROUBLESHOOTING 13.4 BATTERY INSPECTION 13.2 IGNITION COIL 13.5 CHARGING 13.3 BATTERY CAUTION 13.6 WIRING DIAGRAMS 13.1 TROUBLESHOOTING...

  • Page 115: Ignition Coil

    13.2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0.1 - 0.3Ω (20°C) Measure the secondary coil resistance with the spark plug cap in place. STANDARD : 7.4 –...

  • Page 116: Battery Caution

    13.3 BATTERY CAUTION CAUTION The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an open area. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns.
  • Page 117 13.6 WIRING DIAGRAMS (ONLY FOR VIPER 90R) ¥N¸¹ Color ¥N¸¹ Color BATTERY(MF) Transmission Black/White Black START START MAG. SW. MOTOR 12V 5AH Selector Switch White/Black Key Ignition Switch Brake Switch Rectifier Black/Yellow Fuse Box Brown LOCK Purple Black/Red Yellow White/Red White Yellow/Red Gray...
  • Page 118 WIRING DIAGRAMS (FOR VIPER 70 & 90) BATTERY(MF) START ¥N¸¹ Color Brake Switch START MAG. SW. MOTOR 12V 4AH Rectifier Key Ignition Switch Black Fuse Box Brown Black/Red White Yellow/Red Green Black/White Green/Yellow Blue/Yellow White/Black White/Red Red/Black Handle Bar Switch (LH) Engine Stop Switch Starter Button C.D.I.
  • Page 119 14.TROUBLESHOOTING 14.1 ENGINE DOES NOT START 14.4 LOSS POWER 14.2 POOR PERFORMANCE AT LOW AND 14.5 POOR HANDLING IDLE SPEEDS 14.3 POOR PERFORMANCE AT HIGH SPEED 14.1 ENGINE DOES NOT START...
  • Page 120 14.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 14.3 POOR PERFORMANCE AT HIGH SPEED...
  • Page 121 14.4 LOSS POWER...
  • Page 122 14.5 POOR HANDLING...

This manual is also suitable for:

Viper 90r silver

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